Method to consolidate fine granular material

ABSTRACT

A METHOD FOR THE COMPACTION OF THE FINE GRANULAR MATERIAL FORMING THE DESIGN ON A SHEET FLOOR COVERING. A THIN, FLEXIBLE METAL SHEET IS ATTACHED TO THE UNDERSIDE OF THE PRESS PLATE AND THE METAL SHEET SAGS TOWARDS ITS CENTER PORTION. WHEN THE PRESS CLOSES, THE CENTRAL PORTION OF THE SAGGING SHEET INITIALLY CONTACTS THE GRANULAR MATERIAL   AND FORCES THE AIR OUT FROM UNDER THE PRESS BY THE GRADUAL EXPULSION OF THE AIR FROM BETWEEN THE PRESS AND THE GRANULAR MATERIAL AND FROM WITHIN THE GRANUALR MATERIAL.

June 8, 1971' E. J. LANDlS 3,584,10@

METHOD TO CONSOLIDATE FINE GRANULAR MATERIAL Original Filed Dec. 2 1966 2 Sheets-Sheet 1 INVENTUR ELMER .1. LAN DIS W. A) Q 51;,

ATTURIH-Y Jufi8, 1971 E. J.LANDIS 3,584,100

METHOD TO CONSOLIDATE FINE GRANULAR MATERIAL Original Filed Dec. 2. 1966 2 Sheets-Sheet B INVENTUR ELMER .J. LANDIS BIY ATTORNEY United States Patent O 3,584,100 METHOD TO CONSOLIDATE FINE GRANUIJAR MATERIAL Elmer J. Landis, Lancaster, Pa., assignor to Armstrong Cork Company, Lancaster, Pa. Original application Dec. 2, 1966, Ser. No. 598,814. Divided and this application June 17, 1969, Ser.

Int. Cl. B29j /04 US. Cl. 264-120 1 Claim ABSTRACT OF THE DISCLOSURE CROSS REFERENCE TO RELATED APPLICATION This is a division of application Ser. No. 598,814, filed Dec. 2, 1966 and now abandoned.

BACKGROUND OF THE INVENTION A fine granular material is placed on a carrier through the use of stencils to form a pattern arrangement. Consolidation of the fine granular material into the unitary structure is normally accomplished by the use of heated presses. The flat press plate coming down against the granular material results in a sudden large momentary air flow as air is forced from between the press plate and the surface of the granular material and from within the mix of granular material. This air movement tends to disturb and disorient the pattern formed by the granular material.

A partial solution to the problem was the use of a preliminary pressing operation using a large metal plate prior to the consolidation by the heated press. The large metal plate as it pressed down upon the granular material would compact the material so that the air fiow pattern developed in the heated press would not disturb the pattern arrangement. However, the large metal plate for compaction also tended to generate an air flow pattern since it is also a flat plate.

SUMMARY The invention is related to a method for eliminating large rapid air flow patterns beneath press plates acting on fine granular material.

The invention specifically uses a sagging thin flexible metal sheet attached to the underside of a press plate to secure gradual expulsion of air from between the press plate and the sheet goods. The thin sheet initially contacts the center of the goods and forces air out from under the press plate with a gentle rolling action.

BRIEF DESCRIPTION OF THE DRAWING FIG. 1 is a perspective view of the press plate in position;

FIG. 2 is a side view With the press plate in the raised position;

FIG. 3 is a side view with the press plate in its lowered position; and

FIG. 4 is an enlarged view of the mounting of the metal sheet on the press plate.

3,584,100 Patented June 8, 1971 "ice DESCRIPTION OF THE PREFERRED EMBODIMENT The invention deals with a preliminary compaction method employed in the treatment of fine granular material used to form a sheet good. The granular material is placed in a certain pattern arrangement on a carrier structure by use of stencils. The granular material is consolidated into a unitary mass by a two-stage press structure that applies heat and upward to 1,200 pounds per inch pressure to the granular material to accomplish the consolidation into a unitary structure.

The specific invention is related to a method for accomplishing compaction of the granular material prior to its treatment by the heated two-stage presses. Due to the nature of the heated presses, the large flat press head moving down against the flat pattern of granular material results in a rapid expulsion of air from within the mixture of granular materials and between the press and the granular material forming the sheet good. This rapid expulsion of air will disturb the pattern formed by the granular material. This situation is corrected by the use of a compaction press plate 2 which compacts the granular material to such an extent that the air flow generated in the heated presses will not disturb the pattern arrangement. The granular mix 4 is distributed in a pattern ar rangement on a carrier belt 6 traveling over a support table 8. The granular mix and carrier belt move in the direction 10 towards the heated presses.

The compaction press plate 2 moves upwardly and downwardly away from and against the granular mix dependent upon the intermittent operation of the carrier belt 6. The compaction press plate 2 is composed of a large metal plate 12 carrying a sagging thin flexible metal sheet 14. As seen in FIG. 2, the sheet 14 suspended below the large metal plate 12 slopes downwardly towards its center portion under the metal plate.

As seen in FIG. 4, the metal sheet 14 passes completely around the metal plate 12 and its sag is adjusted by the use of adjusting screws 16 carried by adjusting bar 18. Movement of the adjusting screw 16 inwardly towards the plate 12 causes adjusting bar 18 to move outwardly away from plate 12 and diminishes the sag of the metal sheet 14. The space between the head of screw 16 and bar 18 permits slight movement of the ends of the sheet to allow upward movement of the sheet when the plate moves downward.

Plate 12 is supported by side rails 20 and adjusting screws 22. The side rails 20 are moved upwardly and downwardly, as shown by arrows 24, by mechanical lift devices 26. The lift devices 26 raise and lower the metal plate 12 in response to the intermittent operation of the carrier 6.

FIG. 2 shows the metal plate 12 in its raised position with the metal sheet 14 sagging centrally of the metal plate and positioned just above the granular mix 4. FIG. 3 shows the metal plate 12 in its lowermost position with the metal sheet 14 flush against the lower surface of the metal plate 12 and pressing upon the granular mix 4 to accomplish compaction. As the metal plate 12 moved downwardly, the central portion of the sagging sheet 12 first engages the granular mix. Continued downward movement of the metal plate 12 causes more of the sheet 14 to engage the granular mix. The contact area between the sheet 14 and the granular mix 4 progresses outwardly right and left (FIG. 2) from the center sagging portion of the sheet 14. This grandual progressing contact right and left between the sheet 14 and the granular mix 4 results in a gradual expulsion of the air from between the compaction press and the granular mix and from within the mixture of the granular material. This gradual expulsion of air does not disturb the pattern arrangement of the granular mix.

The metal plate 12, after the gradual expulsion of air, compacts the granular mix 4 so that the later consolidation of the granular mix by the heated presses will not result in a pattern disorientation by the expelled air from the heated press plates.

While certain preferred embodiments of the invention have been specifically disclosed, it is understood that the invention is not limited thereto, as many variations will be readily apparent to those skilled in the art and the invention is to be given its broadest possible interpretation within the terms of the following claim.

I claim:

1. A method of consolidating a mix of fine granular material, comprising:

(a) placing a layer of said granular material in a patterned arrangement on a carrier belt traveling over a support table,

(b) positioning said granular material under a flat press plate having :a flexible thin metal sheet suspended below and sagging downwardly under said press plate,

() moving said press plate and said sagging sheet downwardly to engage said sheet with said granular material, first at the center of said granular material, and during further downward movement of said press plate, said sheet progressively increasing its engagement with said granular material to permit gradual expulsion of air from within said granular material and between said sheet and said granular material, leaving undisturbed said pattern arrangement in said granular material, and

(d) applying heat and pressure by said press plate through the flattened thin sheet to consolidate said granular material.

References Cited UNITED STATES PATENTS 1,206,656 11/1916 B'enedictus 25-102 2,867,843 1/ 1959 Browne et a1. 18-Vent Digest 2,838,796 6/1958 Reed 18Fluid Press Dig. 3,103,038 9/1963 Zolton 25-45 ROBERT F. WHITE, Primary Examiner I. R. HALL, Assistant Examiner US. Cl. X.R. 264--316 

